Thermally insulated wall anchor

ABSTRACT

A wall anchor for use in a cavity wall to connect to a veneer tie that joins an inner wythe and an outer wythe of the cavity wall includes an elongated shaft and a receiving section configured to be in attachment with the elongated shaft. The receiving section defines at least one aperture configured to receive a portion of the veneer tie. The receiving section defines a thermal insulating member comprising non-metallic material. The receiving section has no metallic material surrounding the at least one aperture and is configured such that no metallic material is exposed out of the receiving section to an air cavity between the inner wythe and outer wythe when the wall anchor is in an installed state.

CROSS-REFERENCE TO RELATED APPLICATIONS

Not applicable.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

INCORPORATION BY REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC

Not applicable.

TECHNICAL FIELD

The present invention relates to the field of anchoring systems forcavity walls, and more specifically, to the field of thermally insulatedwall anchors for preventing the flow of thermal energy betweenconductive materials within a wall assembly.

BACKGROUND

Minimizing the use of energy and natural resources are vital componentsof the global strategy to protect the environment and mitigate climatechange. Buildings and the construction sector represent a large portionof total global energy and resource consumption. One significant aspectof energy loss from a building is conductive heat transfer through thebuilding envelope. The building envelope is a layer of the buildingenclosure system that resists heat flow between the interior conditionedenvironment and the exterior unconditioned environment. The thermalperformance of the building envelope can be greatly affected by thermalbridging. Thermal bridges are localized elements or assemblies thatpenetrate insulated portions of the building envelope with thermallyconductive materials that result in high levels of heat loss.

Determining and preventing potential thermal bridges within a cavitywall is essential for constructing a comfortable and energy efficiencybuilding. Thermal bridging typically occurs near highly conductivematerials like wood studs, metal studs, steel, and concrete. Thermalbridging can result in increased energy required to heat or cool aconditioned space due to winter heat loss and summer heat gain. Forexample, in a climate where the interior temperatures are greater thanthe exterior, heat from a room will eventually transfer through theinterior drywall and to the highly conductive flanges of a stud, routingto the fastener of a brick tie, to the tie itself, and eventuallyexiting the brick at the exterior, resulting in a reduction of thermalperformance of the wall assembly.

Additionally, when the temperature difference between indoor and outdoorspace is large, and there is warm and humid air indoors, such as theconditions experienced in the winter, there is a risk of condensation inthe building envelope due to the cooler temperature on the interiorsurface at thermal bridge locations. Condensation may ultimately resultin mold growth with consequent poor indoor air quality and insulationdegradation, reducing the insulation performance and causing theinsulation to perform inconsistently throughout the thermal envelope.

Although traditional methods to reduce thermal bridging, such aslimiting the number of wall anchors that span from unconditioned toconditioned space and utilizing wall anchors coated with non-conductivematerials improve energy efficiency, the inability to completelyeliminate the metal components of a wall anchor from within the cavitywall continues to cause heating and cooling losses. Therefore, a needexists to improve over the prior art and, more particularly, for aninsulated wall anchor that eliminates metal components within a cavitywall for preventing the flow of thermal energy while also conservingstructural integrity.

SUMMARY

A thermally insulated wall anchor for use in a cavity wall to connect toa veneer tie that joins an inner wythe and an outer wythe of the cavitywall is disclosed. This Summary is provided to introduce a selection ofdisclosed concepts in a simplified form that are further described belowin the Detailed Description, including the drawings provided. ThisSummary is not intended to identify key features or essential featuresof the claimed subject matter. Nor is this Summary intended to be usedto limit the claimed subject matter's scope.

In one embodiment, a wall anchor for use in a cavity wall to connect toa veneer tie that joins an inner wythe and an outer wythe of the cavitywall is disclosed. The wall anchor includes an elongated shaft and areceiving section configured to be in attachment with the elongatedshaft. The receiving section defines at least one aperture configured toreceive a portion of the veneer tie. The receiving section defines athermal insulating member comprising non-metallic material. Thereceiving section has no metallic material surrounding the at least oneaperture and is configured such that no metallic material is exposed outof the receiving section to an air cavity between the inner wythe andouter wythe when the wall anchor is in an installed state.

In one embodiment, a wall anchor for use in a cavity wall to connect toa veneer tie that joins an inner wythe and an outer wythe of the cavitywall is disclosed. The wall anchor includes an elongated shaft and areceiving section configured to be in attachment with the elongatedshaft. The receiving section defines at least one aperture configured toreceive a portion of the veneer tie. The receiving section defines athermal insulating member comprising non-metallic material. Thereceiving section is configured such that no metallic material of thereceiving section is between the inner wythe and outer wythe when thewall anchor is in an installed state.

In one embodiment, a method of anchoring a veneer wall to an inner wythefor horizontal load transfer is disclosed. The method includes securingan anchoring end of an anchor shaft of a wall anchor to an inner wythesuch that a receiving end of the wall anchor protrudes into a spacebetween the inner wythe and the outer wythe such that no metallicmaterial is exposed out of the receiving section to an air cavitybetween the inner wythe and outer wythe when the wall anchor is in aninstalled state.

Additional aspects of the disclosed embodiment will be set forth in partin the description which follows, and in part will be obvious from thedescription, or may be learned by practice of the disclosed embodiments.The aspects of the disclosed embodiments will be realized and attainedby means of the elements and combinations particularly pointed out inthe appended claims. It is to be understood that both the foregoinggeneral description and the following detailed description are exemplaryand explanatory only and are not restrictive of the disclosedembodiments, as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute partof this specification, illustrate embodiments of the invention andtogether with the description, serve to explain the principles of thedisclosed embodiments. The embodiments illustrated herein are presentlypreferred, it being understood, however, that the invention is notlimited to the precise arrangements and instrumentalities shown,wherein:

FIG. 1 is a front view of a wall anchor for use in a cavity wall,according to a first example embodiment of the present invention;

FIG. 2 is a right-side view of a wall anchor for use in a cavity wall,according to an example embodiment of the present invention;

FIG. 3 is a left-side view of a wall anchor for use in a cavity wall,according to an example embodiment of the present invention;

FIG. 4 is a perspective right-side view of a wall anchor for use in acavity wall, according to an example embodiment of the presentinvention;

FIG. 5 is a perspective left-side view of a wall anchor for use in acavity wall, according to an example embodiment of the presentinvention;

FIG. 6 is a front view of a wall anchor for use in a cavity wall,wherein a second end of the elongated shaft includes a self-drillingpoint that is configured for use with metal, according to an exampleembodiment of the present invention;

FIG. 7 is a perspective view of a receiving section, wherein a flange ofthe receiving section is defined by an oval shape, according to anexample embodiment of the present invention;

FIG. 8 is a perspective view of a receiving section, wherein a flange ofthe receiving section is defined by a 12-point star-shaped pattern,according to an example embodiment of the present invention;

FIG. 9 is a perspective view of a receiving section, wherein a flange ofthe receiving section is defined by at least one recess, according to anexample embodiment of the present invention;

FIG. 10 is a cross sectional view of a wall anchor in an installedstate, wherein the receiving section is configured such that no metallicmaterial of the receiving section is exposed to an air cavity betweenthe inner wythe and outer wythe, according to an example embodiment ofthe present invention;

FIG. 11 is a cross sectional view of a wall anchor in an installedstate, wherein the receiving section is configured such that no metallicmaterial of the receiving section is between the inner wythe and outerwythe, according to an example embodiment of the present invention;

FIG. 12 is a top view of a veneer tie attached to a wall anchor for usein a cavity wall, according to an example embodiment of the presentinvention;

FIG. 13 is a side view of a veneer tie attached to a wall anchor for usein a cavity wall, according to an example embodiment of the presentinvention;

FIG. 14 is a perspective right-side view of a veneer tie attached to awall anchor for use in a cavity wall, according to an example embodimentof the present invention;

FIG. 15 is a front view of a wall anchor for use in a cavity wall,according to a second example embodiment of the present invention;

FIG. 16 is a right-side view of a wall anchor for use in a cavity wall,according to an example embodiment of the present invention;

FIG. 17 is a left-side view of a wall anchor for use in a cavity wall,according to an example embodiment of the present invention;

FIG. 18 is a perspective right-side view of a wall anchor for use in acavity wall, according to an example embodiment of the presentinvention;

FIG. 19 is a perspective left-side view of a wall anchor for use in acavity wall, according to an example embodiment of the presentinvention;

FIG. 20 is a front view of a wall anchor for use in a cavity wall,wherein a second end of the elongated shaft includes a self-drillingpoint that is configured for use with metal, according to an exampleembodiment of the present invention;

FIG. 21 is a right-side view of a receiving section, wherein an outwardfacing end of the receiving section includes a hexagon-shapedprotrusion, according to an example embodiment of the present invention;

FIG. 22 is a front view of a receiving section, wherein an outwardfacing end of the receiving section includes a hexagon shapedprotrusion, according to an example embodiment of the present invention;

FIG. 23 is a right-side view of a receiving section, wherein an outwardfacing end of the receiving section includes two recesses, according toan example embodiment of the present invention;

FIG. 24 is a front view of a receiving section, wherein an outwardfacing end of the receiving section includes two recesses, according toan example embodiment of the present invention;

FIG. 25 is a right-side view of a receiving section, wherein an outwardfacing end of the receiving section includes four recesses, according toan example embodiment of the present invention;

FIG. 26 is a front view of a receiving section, wherein an outwardfacing end of the receiving section includes four recesses, according toan example embodiment of the present invention;

FIG. 27 is a cross sectional view of a wall anchor in an installedstate, wherein the receiving section is configured such that no metallicmaterial of the receiving section is exposed to an air cavity betweenthe inner wythe and outer wythe, according to an example embodiment ofthe present invention;

FIG. 28 is a cross sectional view of a wall anchor in an installedstate, wherein the receiving section is configured such that no metallicmaterial of the receiving section is between the inner wythe and outerwythe, according to an example embodiment of the present invention;

FIG. 29 is a top view of a veneer tie attached to a wall anchor for usein a cavity wall, according to an example embodiment of the presentinvention;

FIG. 30 is a side view of a veneer tie attached to a wall anchor for usein a cavity wall, according to an example embodiment of the presentinvention;

FIG. 31 is a perspective right-side view of a veneer tie attached to awall anchor for use in a cavity wall, according to an example embodimentof the present invention; and

FIG. 32 is a flowchart describing the steps of the process for preparinga cooked food item, according to an example embodiment of the presentinvention.

DETAILED DESCRIPTION

The following detailed description refers to the accompanying drawings.Whenever possible, the same reference numbers are used in the drawingsand the following description to refer to the same or similar elements.While disclosed embodiments may be described, modifications,adaptations, and other implementations are possible. For example,substitutions, additions, or modifications may be made to the elementsillustrated in the drawings, and the methods described herein may bemodified by substituting reordering or adding additional stages orcomponents to the disclosed methods and devices. Accordingly, thefollowing detailed description does not limit the disclosed embodiments.Instead, the proper scope of the disclosed embodiments is defined by theappended claims.

The present invention improves upon the prior art by providing a wallanchor for use in a cavity wall to connect to a veneer tie that joins aninner wythe and an outer wythe of the cavity wall. The wall anchorincludes an elongated shaft and a receiving section configured to be inattachment with the elongated shaft. The receiving section defines athermal insulating member that is comprised of a non-metallic materialand is coated with a high temperature coating. The receiving section isconfigured such that no metallic material is exposed out of thereceiving section to an air cavity between the inner wythe and outerwythe when the wall anchor is in an installed state. The presentinvention further improves upon the prior art because the receivingsection is configured such that no metallic material of the receivingsection is between the inner wythe and outer wythe when the wall anchoris in an installed state.

Referring now to the Figures, FIGS. 1-5 illustrate a wall anchor 100 foruse in a cavity wall 102 to connect to a veneer tie 104 that joins aninner wythe 106 and an outer wythe 108 of the cavity wall 102, accordingto a first embodiment of the present invention and will be discussedtogether for ease of reference. The wall anchor 100 includes anelongated shaft 120 defining a fully threaded cylindrical shape thatextends from a first end 122 to a second end 124. The first end 122 ofthe elongated shaft 120 is configured to be in attachment with areceiving section 130, as further discussed below. The second end 124 ofthe elongated shaft 120 is configured to be driven into the inner wythe106 of the cavity wall 102. The elongated shaft may be attached to thereceiving section in a variety of manners including an extrusionprocess, forging a mold, welding, shearing, punching welding, foldingetc. However, other types of processes may also be used and are withinthe spirit and scope of the present invention.

In one embodiment, the second end 124 of the elongated shaft 120includes a sharp tapered tip 126 configured for attachment to materialssuch as sheet metal, wood, and drywall. In one embodiment, as bestillustrated in FIG. 6, the second end 124 of the elongated shaft 120includes a self-drilling tip 127 configured for attachment to materialssuch as metal and wood. In operation, the self-drilling tip acts as adrill bit for the elongated shaft. Specifically, a notch 128 on theself-drilling tip functions as a reservoir to receive wood chips ormetal filings to create the space necessary to drive the elongated shaft120 into the inner wythe 106 of the cavity wall 102.

It should be appreciated that depending on the method and application ofthe wall anchor, the elongated shaft may comprise a broad range ofdiameters, lengths, drive styles, threads, and finishes, and suchvariations are within the spirit and scope of the claimed invention. Itshould also be appreciated that the elongated shaft 120 may be made ofany suitable material, such as stainless steel or zinc-plated steel, orcombination of materials, and may vary in accordance with the presentinvention. As further discussed below, the elongated shaft 120 mayfurther include a high temperature coating to reduce thermalconductivity.

The wall anchor 100 further includes a receiving section 130 that isconfigured to be in attachment with the elongated shaft 120. Thereceiving section includes an outward facing end 132 and an inwardfacing end 133. In one embodiment, the outward facing end 132 of thereceiving section includes an outwardly extending tab 181 comprising asubstantially planar rectangular shaped body. The outward facing end 132of the receiving section further includes at least one aperture 180 thatis configured to receive a portion of the veneer tie 104. In oneembodiment, the aperture is defined by an oval shaped opening formed onthe outwardly extending tab of the receiving section. The inner diameterof the aperture is sized and shaped according to the outer diameter ofthe veneer tie 104.

In operation, as best shown in FIGS. 12-14, the veneer tie 104 isinserted into the aperture of the receiving section to secure the veneertie to the wall anchor 100. The veneer tie is configured to resistcompressive and tensile loads that arise from lateral loads, such asfrom wind or seismic excitation. It should be appreciated that theaperture may have a variety of cross-sectional shapes andconfigurations, and such variations are within the spirit and scope ofthe claimed invention. The aperture on the receiving section may bemanufactured from a variety of different processes such as punching,stamping, scissoring, flame cutting, laser cutting, sawing, drilling,milling, or turning.

The inward facing end 233 of the receiving section includes a collaredsection 140. The collared section 140 is configured to be in attachmentwith the first end 122 of the elongated shaft 120. In one embodiment,the collared section 140 is a hollow cylindrical shaped body having acircular shaped opening 141. The collared section 140 includes an innerdiameter that is larger than an outer diameter of the elongated shaftsuch that the first end 122 of the elongated shaft 120 may be insertedinto the circular shaped opening 141 of the collared section. It shouldbe appreciated that the collared section 140 may have include differentshapes, dimensions, and configurations, and such variations are withinthe spirit and scope of the claimed invention.

The wall anchor 100 further includes a flanged section 150 locatedbetween the collared section 140 and the receiving section 130. Theflanged section 150 defines a shape that is configured to engage with atool that provides a driving force to drive the second end 124 of theelongated shaft 120 into the inner wythe 106 such that the aperture isnot damaged during installation. It should be appreciated that theflanged section 150 may have various shapes and dimensions, and suchvariations are within the spirit and scope of the claimed invention.

For example, in one embodiment, as best shown in FIG. 2, the flangedsection 150 is defined by a hexagonal shape. In one embodiment, as bestshown in FIG. 7, the flanged section 150 is defined by an oval shape. Inone embodiment, as best shown in FIG. 8, the flanged section 150 isdefined by a 12-point star-shaped pattern. In one embodiment, as bestshown in FIG. 9, the flanged section 150 is defined by at least onerecess 178 (three are shown) located on the outward facing end 132 ofthe receiving section 130. It should be appreciated that the recess mayhave a variety of cross-sectional shapes and configurations, and suchvariations are within the spirit and scope of the claimed invention. Inone embodiment, the wall anchor is part of a kit that includes a toolthat is configured to engage with a shape of the flanged section 150 toprovide a driving force to drive the second end 124 of the elongatedshaft 120 into the inner wythe 106.

The wall anchor 100 further includes a washer 160 that abuts an inwardfacing surface of the flanged section 150. The washer 160 is configuredto completely seal the opening into the inner wythe 106. The washer 160includes an outward facing surface 161 and an inward facing surface 162.In one embodiment, the washer 160 comprises a substantially planarcircular shaped body that extends beyond the flange of the wall anchor.The washer 160 may be comprised of a stabilizing neoprene fitting, or abonded sealing washer, such as a sealing washer having a backing (e.g.,nylon) with a bonded sealant (e.g., EPDM rubber, neoprene, silicone), orany other suitable material known in the art. It should be appreciatedthat the washer 160 may be omitted from the wall anchor or may haveother shapes and dimensions, and such variations are within the spiritand scope of the claimed invention.

As discussed in greater detail below, the receiving section 130 of thewall anchor defines a thermal insulating member comprising non-metallicmaterial for preventing the flow of thermal energy. The receivingsection 130 of the wall anchor is made from a high temperature materialcomprising at least one of an ablative material, a boron fiber material,a carbon fiber material, a ceramic matrix composite material, acomposite material, an epoxy matrix composite, a fatigue compositematerial, a fiber composite, a fiber-matrix interface, a filamentmaterial, a filament wound structures composite material, afilament-matrix material, a flammability composite materials, a glassfiber reinforced plastic material, a honeycomb material, an insulationcomposite material, a laminate material, a metal filament system, ametal matrix composite (MMC), a nanocomposite, anoff-gassing/out-gassing composite material, a polymer matrix composite,a reinforcing fibers composite material, a stacking sequence compositematerial, a surface property composite material, whisker composite, awoven composite material, or any combination of the foregoing materials.

The receiving section 130 of the wall anchor further includes a hightemperature coating selected from thermoplastics, thermosets, naturalfibers, rubbers, resins, asphalts, ethylene propylene diene monomers,and admixtures thereof and may be applied in layers. The hightemperature coating optionally contains an isotropic polymer, whichincludes, but is not limited to, acrylics, nylons, epoxies, silicones,polyesters, polyvinyl chlorides, polyethylene, and chlorosulfonatedpolyethylene. Alternatively, the high temperature coating may be aceramic or ceramic-based coating including materials selected fromlanthanum, cerium, praseodymium, neodymium, promethium, samarium,europium, gadolinium, terbium, dysprosium, holmium, erbium, thulium,ytterbium, lutetium, indium, scandium, yttrium, zirconium, hafnium,titanium, silica, zirconia, magnesium zirconate, yttria-stabilizedzirconia, and derivatives and admixtures thereof. An initial layer ofthe high temperature coating may be cured to provide a pre-coat, and thelayers of the high temperature coating may be cross-linked to providehigh-strength adhesion to the wall anchor to resist chipping or wearingof the high temperature coating. The high temperature coating may beapplied through any number of methods, including fluidized bedproduction, thermal spraying, hot dip processing, heat-assisted fluidcoating, or extrusion, and includes both powder and fluid coating toform a reasonably uniform coating.

The present invention improves upon the prior art by removing contactwith metal components within a cavity wall to prevent the flow ofthermal energy. In operation, as best shown in the embodiment of FIG.10, the receiving section 130 is configured such that no metallicmaterial is exposed out of the receiving section to an air cavity 109between the inner wythe and outer wythe when the wall anchor is in aninstalled state. Specifically, the receiving section enclosed in thedashed area 182 is comprised of non-metallic material to prevent theflow of thermal energy. Thus, unlike the prior art, the receivingsection has no metallic material surrounding the aperture. Therefore,although the first end 122 of the elongated shaft 120 is located betweenthe inner wythe and outer wythe, no metallic material is exposed out ofthe receiving section to the air cavity 109 between the inner wythe andouter wythe because the receiving section 130 of the wall anchorincludes the thermal insulating member that prevents the flow of thermalenergy.

In one embodiment, as best shown in FIG. 11, the receiving section 130is configured such that there is no metallic material located betweenthe inner wythe and outer wythe when the wall anchor is in an installedstate. As discussed above, the receiving section enclosed in the dashedarea 182 (including the body 183 surrounding the aperture 180) iscomprised of non-metallic material to prevent the flow of thermalenergy. In addition to the thermal insulating member preventing the flowof thermal energy, the first end 122 of the elongated shaft 120 isfurther confined to a portion of the collared section such that it iscompletely removed from between the inner wythe and outer wythe.

FIGS. 15-19 illustrate a wall anchor 200 for use in a cavity wall 202 toconnect to a veneer tie 204 that joins an inner wythe 206 and an outerwythe 208 of the cavity wall 202, according to a second embodiment ofthe present invention and will be discussed together for ease ofreference. The wall anchor 200 includes an elongated shaft 220 defininga fully threaded cylindrical shape that extends from a first end 222 toa second end 224. The first end 222 of the elongated shaft 220 isconfigured to be in attachment with a receiving section 230, as furtherdiscussed below. The second end 224 of the elongated shaft 220 isconfigured to be driven into the inner wythe 206 of the cavity wall 202.

In one embodiment, the second end 224 of the elongated shaft 220includes a sharp tapered tip 226 configured for attachment to materialssuch as sheet metal, wood, and drywall. In one embodiment, as bestillustrated in FIG. 20, the second end 224 of the elongated shaft 220includes a self-drilling tip 227 configured for attachment to materialssuch as metal and wood. In operation, the self-drilling tip acts as adrill bit for the elongated shaft. Specifically, a notch 228 on theself-drilling tip functions as a reservoir to receive wood chips ormetal filings to create the space necessary to drive the elongated shaft220 into the inner wythe 206 of the cavity wall 202.

It should be appreciated that depending on the method and application ofthe wall anchor, the elongated shafted may comprise a broad range ofdiameters, lengths, drive styles, threads, and finishes, and suchvariations are within the spirit and scope of the claimed invention. Itshould also be appreciated that the elongated shaft 220 may be made ofany suitable material, such as stainless steel or zinc-plated steel, orcombination of materials, and may vary in accordance with the presentinvention. As further discussed below, the elongated shaft 220 mayfurther include a high temperature coating to reduce thermalconductivity.

The wall anchor 200 further includes a receiving section 230 that isconfigured to be in attachment with the elongated shaft 220. Thereceiving section includes an outward facing end 232 and an inwardfacing end 233. The outward facing end 232 of the receiving section isconfigured to engage with a tool that provides a driving force to drivethe second end 224 of the elongated shaft 220 into the inner wythe 206.For example, in one embodiment, the outward facing end 232 of thereceiving section is defined by at least one hexagonally shaped recess278. In one embodiment, as best shown in FIGS. 21 and 22, the outwardfacing end 232 of the receiving section is defined by at least oneoutwardly extending hexagonally shaped bolt. In one embodiment, as bestshown in FIGS. 23 and 24, the outward facing end 232 of the receivingsection is defined by two circular shaped recesses 278. In oneembodiment, as best shown in FIGS. 25 and 26, the outward facing end 232of the receiving section is defined by four circular shaped recesses278. It should be appreciated that the recess may have a variety ofcross-sectional shapes and configurations, and such variations arewithin the spirit and scope of the claimed invention. In one embodiment,the wall anchor is part of a kit that includes a tool that is configuredto provide a driving force to drive the second end 224 of the elongatedshaft 220 into the inner wythe 206. The tool may be configured to engagewith the outward facing end of the receiving section. For example, incertain embodiments, the tool is configured to engage with the recesseson the receiving section. In other embodiments, the tool is configuredto engage with the hexagonal head of the receiving section, however itis understood that other embodiments may be used and are within thespirit and scope of the present invention.

The inward facing end 233 of the receiving section includes a collaredsection 240. The collared section 240 is configured to be in attachmentwith the first end 222 of the elongated shaft 220. In one embodiment,the collared section 240 is a hollow cylindrical shaped body having acircular shaped opening 241. The collared section 240 includes an innerdiameter that is larger than an outer diameter of the elongated shaftsuch that the first end 222 of the elongated shaft 220 may be insertedinto the circular shaped opening 241 of the collared section. It shouldbe appreciated that the collared section 240 may have include differentshapes, dimensions, and configurations, and such variations are withinthe spirit and scope of the claimed invention.

The wall anchor 200 further includes a flanged section 250 locatedbetween the collared section 240 section and the receiving section 230.In one embodiment, the flanged section 250 is defined by a wing nut. Theflanged section 250 further includes at least one aperture 280 that isconfigured to receive a portion of the veneer tie 204. In oneembodiment, the aperture is defined by a circular shaped opening (twoare shown) formed on the flanged section. The inner diameter of theaperture is sized and shaped according to the outer diameter of theveneer tie 204.

In operation, as best shown in FIGS. 29-31, the veneer tie 204 isinserted into the aperture to secure the veneer tie to the wall anchor200. The veneer tie is configured to resist compressive and tensileloads that arise from lateral loads, such as from wind or seismicexcitation. It should be appreciated that the aperture may have avariety of cross-sectional shapes and configurations, and suchvariations are within the spirit and scope of the claimed invention. Theaperture may be manufactured from a variety of different processes suchas punching, stamping, scissoring, flame cutting, laser cutting, sawing,drilling, milling, or turning.

The wall anchor 200 further includes a washer 260 that abuts an inwardfacing surface of the flanged section 250. The washer 260 is configuredto completely seal the opening into the inner wythe 206. The washer 260includes an outward facing surface 261 and an inward facing surface 262.In one embodiment, the washer 260 comprises a substantially planarcircular shaped body that extends beyond the flange of the wall anchor.The washer 260 may be comprised of a stabilizing neoprene fitting, or abonded sealing washer, such as a sealing washer having a backing (e.g.,nylon) with a bonded sealant (e.g., EPDM rubber, neoprene, silicone), orany other suitable material known in the art. It should be appreciatedthat the washer 260 may be omitted from the wall anchor or may haveother shapes and dimensions, and such variations are within the spiritand scope of the claimed invention.

As discussed above, the receiving section 230 of the wall anchor definesa thermal insulating member comprising non-metallic material forpreventing the flow of thermal energy. The receiving section 230 of thewall anchor is made from a high temperature material comprising at leastone of an ablative material, a boron fiber material, a carbon fibermaterial, a ceramic matrix composite material, a composite material, anepoxy matrix composite, a fatigue composite material, a fiber composite,a fiber-matrix interface, a filament material, a filament woundstructures composite material, a filament-matrix material, aflammability composite materials, a glass fiber reinforced plasticmaterial, a honeycomb material, an insulation composite material, alaminate material, a metal filament system, a metal matrix composite(MMC), a nanocomposite, an off-gassing/out-gassing composite material, apolymer matrix composite, a reinforcing fibers composite material, astacking sequence composite material, a surface property compositematerial, whisker composite, a woven composite material, or anycombination of the foregoing materials.

The receiving section 230 of the wall anchor further includes a hightemperature coating selected from thermoplastics, thermosets, naturalfibers, rubbers, resins, asphalts, ethylene propylene diene monomers,and admixtures thereof and may be applied in layers. The hightemperature coating optionally contains an isotropic polymer, whichincludes, but is not limited to, acrylics, nylons, epoxies, silicones,polyesters, polyvinyl chlorides, polyethylene, and chlorosulfonatedpolyethylene. Alternatively, the high temperature coating may be aceramic or ceramic-based coating including materials selected fromlanthanum, cerium, praseodymium, neodymium, promethium, samarium,europium, gadolinium, terbium, dysprosium, holmium, erbium, thulium,ytterbium, lutetium, indium, scandium, yttrium, zirconium, hafnium,titanium, silica, zirconia, magnesium zirconate, yttria-stabilizedzirconia, and derivatives and admixtures thereof. An initial layer ofthe high temperature coating may be cured to provide a pre-coat, and thelayers of the high temperature coating may be cross-linked to providehigh-strength adhesion to the wall anchor to resist chipping or wearingof the high temperature coating. The high temperature coating may beapplied through any number of methods, including fluidized bedproduction, thermal spraying, hot dip processing, heat-assisted fluidcoating, or extrusion, and includes both powder and fluid coating toform a reasonably uniform coating.

The present invention improves upon the prior art by removing contactwith metal components within a cavity wall to prevent the flow ofthermal energy. In operation, as best shown in the embodiment of FIG.27, the receiving section 230 illustrated in FIGS. 21 and 22 isconfigured such that no metallic material is exposed out of thereceiving section to an air cavity 209 between the inner wythe and outerwythe when the wall anchor is in an installed state. Specifically, thereceiving section enclosed in the dashed area 282 (including outwardfacing end 232) is comprised of non-metallic material to prevent theflow of thermal energy. Therefore, unlike the prior art, the receivingsection has no metallic material surrounding the aperture. In the priorart, there may be devices that have a metallic material coated by anon-metallic material, which results in the aperture being surrounded bymetallic material and coated by non-metallic material. In the presentinvention, therefore, although the first end 222 of the elongated shaft220 is located between the inner wythe and outer wythe, no metallicmaterial is exposed out of the receiving section to the air cavity 209between the inner wythe and outer wythe because the receiving section230 of the wall anchor includes the thermal insulating member thatprevents the flow of thermal energy.

In one embodiment, as best shown in FIG. 28, the receiving section 230is configured such that there is no metallic material located betweenthe inner wythe and outer wythe when the wall anchor is in an installedstate. As discussed above, the receiving section enclosed in the dashedarea 282 is comprised of non-metallic material to prevent the flow ofthermal energy. In addition to the thermal insulating member preventingthe flow of thermal energy, the first end 222 of the elongated shaft 220is further confined to a portion of the collared section such that it iscompletely removed from between the inner wythe and outer wythe.

FIG. 32 is a flowchart describing the steps of the process 300 ofanchoring a veneer wall to an inner wythe for horizontal load transfer,according to an example embodiment of the present invention. Thesequence of steps depicted is for illustrative purposes only and is notmeant to limit the method in any way as it is understood that the stepsmay proceed in a different logical order, additional or interveningsteps may be included, or described steps may be divided into multiplesteps, without detracting from the invention. As described above withrespect to FIGS. 10 and 11, step 305 includes securing an anchoring endof an anchor shaft of a wall anchor to an inner wythe such that areceiving end of the wall anchor protrudes into a space between theinner wythe and the outer wythe such that no metallic material isexposed out of the receiving section to an air cavity between the innerwythe and outer wythe when the wall anchor is in an installed state. Instep 310, the process includes placing a portion of a veneer tie into atleast one aperture of the wall anchor, as shown in FIGS. 13-15.Alternatively, step 305 may be substituted with step 315, wherein theprocess includes securing the receiving end of the wall anchor into theinner wythe such that no metallic material of the receiving section isin the space between the inner wythe and outer wythe.

Although the subject matter has been described in language specific tostructural features and/or methodological acts, it is to be understoodthat the subject matter defined in the appended claims is notnecessarily limited to the specific features or acts described above.Rather, the specific features and acts described above are disclosed asexample forms of implementing the claims.

We claim:
 1. A wall anchor for use in a cavity wall to connect to aveneer tie that joins an inner wythe and an outer wythe of the cavitywall, the wall anchor comprising: an elongated shaft; a receivingsection configured to be in attachment with the elongated shaft; whereinthe receiving section defines at least one aperture configured toreceive a portion of the veneer tie and an abutting section configuredto abut an outward facing surface of the inner wythe; wherein thereceiving section defines a thermal insulating member comprisingnon-metallic material; wherein the receiving section has no metallicmaterial surrounding the at least one aperture; and wherein thereceiving section is free of metallic material up to at least theabutting section.
 2. (canceled)
 3. The wall anchor of claim 2, whereinthe receiving section further comprises a collared section and wherein afirst end of the elongated shaft is in attachment with the collaredsection.
 4. The wall anchor of claim 1, wherein the receiving sectionfurther defines a shape configured to engage with a tool that provides adriving force to drive a second end of the elongated shaft into theinner wythe.
 5. The wall anchor of claim 4, wherein the shape is definedby at least one recess within an outward facing end of the receivingsection.
 6. The wall anchor of claim 3, wherein the wall anchor furtherincludes a flanged section between the collared section and receivingsection.
 7. The wall anchor of claim 6, wherein the abutting sectionalso abuts an inward facing surface of the flanged section.
 8. The wallanchor of claim 1, wherein the receiving section comprises a hightemperature material.
 9. The wall anchor of claim 1, wherein thereceiving section comprises a high temperature coating.
 10. The wallanchor of claim 8, wherein the high temperature material comprises atleast one of an ablative material, a boron fiber material, a carbonfiber material, a ceramic matrix composite material, a compositematerial, an epoxy matrix composite, a fatigue composite material, afiber composite, a fiber-matrix interface, a filament material, afilament wound structures composite material, a filament-matrixmaterial, a flammability composite materials, a glass fiber reinforcedplastic material, a honeycomb material, an insulation compositematerial, a laminate material, a metal filament system, a metal matrixcomposite (MMC), a nanocomposite, an off-gassing/out-gassing compositematerial, a polymer matrix composite, a reinforcing fibers compositematerial, a stacking sequence composite material, a surface propertycomposite material, whisker composite, a woven composite material andany combination of the foregoing material.
 11. The wall anchor of claim9, wherein the high temperature coating comprises at least one of anablative material, a boron fiber material, a carbon fiber material, aceramic matrix composite material, a composite material, an epoxy matrixcomposite, a fatigue composite material, a fiber composite, afiber-matrix interface, a filament material, a filament wound structurescomposite material, a filament-matrix material, a flammability compositematerials, a glass fiber reinforced plastic material, a honeycombmaterial, an insulation composite material, a laminate material, a metalfilament system, a metal matrix composite (MMC), a nanocomposite, anoff-gassing/out-gassing composite material, a polymer matrix composite,a reinforcing fibers composite material, a stacking sequence compositematerial, a surface property composite material, whisker composite, awoven composite material and any combination of the foregoing material.12. A wall anchor for use in a cavity wall to connect to a veneer tiethat joins an inner wythe and an outer wythe of the cavity wall, thewall anchor comprising: an elongated shaft; a receiving sectionconfigured to be in attachment with the elongated shaft; wherein thereceiving section defines at least one aperture configured to receive aportion of the veneer tie, and a washer configured to abut an outwardfacing surface of the inner wythe; wherein the receiving section definesa thermal insulating member comprising non-metallic material; andwherein the receiving section is free of metallic material up to atleast the washer.
 13. The wall anchor of claim 12, wherein the receivingsection further comprises a collared section and wherein a first end ofthe elongated shaft is in attachment with the collared section.
 14. Thewall anchor of claim 12, wherein the receiving section further definesat least one recess within an outward facing end of the receivingsection that is configured to engage with a tool wherein the toolprovides a driving force to drive a second end of the elongated shaftinto the inner wythe.
 15. The wall anchor of claim 13, wherein the wallanchor further includes a flanged section between the collared sectionand receiving section.
 16. The wall anchor of claim 12, wherein thewasher abuts an inward facing surface of the flanged section.
 17. Thewall anchor of claim 12, wherein the receiving section comprises atleast one of a high temperature material and a high temperature coating.18. A method of anchoring a veneer wall to an inner wythe for horizontalload transfer, the method comprising the steps of: securing an anchoringend of an anchor shaft of a wall anchor to an inner wythe such that areceiving end of the wall anchor protrudes into a space between theinner wythe and an outer wythe such that the space between the innerwythe and the outer wythe is free of metallic material when the wallanchor is in an installed state; and placing a portion of a veneer tieinto at least one aperture of the wall anchor.
 19. (canceled)